🏷️ Basic Information

Make:

Harley-Davidson

Model:

FLHRS Road King Custom

Year:

2005

Model Code:

FLHRS

👋 Introduction

Segment:

Cruiser / Touring

Target Audience:

Harley-Davidson owners and independent repair shops seeking detailed service information.

Comparison:

Competes with other large displacement cruisers from manufacturers like Indian and certain Japanese brands, but distinct in its V-twin configuration and classic styling.

Model Style:

Custom styling with a lower profile, extended front end, custom handlebars, and often a different seat design compared to the standard Road King.

Comfort:

Designed for long-distance riding with rider and passenger comfort in mind, featuring forward foot controls and a comfortable riding position.

Heritage:

Continues the legacy of the Road King line, known for its blend of classic styling and touring capability.

📋 Manual Details

Scope:

Complete Workshop Service Repair Manual

Estimated Pages:

Likely 500-800 pages (typical for a comprehensive Harley-Davidson service manual)

Type:

Workshop Service Repair Manual

Language:

English

Format:

Downloadable (typically PDF)

📖 Manual Coverage

Engine:

Detailed coverage of the Twin Cam 88 engine, including disassembly, inspection, assembly, timing, and diagnostics.

Transmission:

Comprehensive repair and maintenance for the 5-speed Cruise Drive transmission.

Fuel System:

Includes fuel injection system (EFI) components, fuel pump, injectors, sensors, and troubleshooting.

Electrical System:

Extensive coverage of wiring diagrams, ignition system, lighting, charging system, starter, and all electronic components.

Brakes:

Front and rear brake system diagnosis, service, and repair, including hydraulic components and pad replacement.

Suspension:

Front fork (including Showa suspension components typical for this model) and rear shock absorber service, adjustment, and replacement.

Chassis And Frame:

Frame inspection, alignment, and related structural components.

Bodywork And Fenders:

Removal, installation, and adjustment of body panels, fenders, saddlebags, and fairings specific to the Road King Custom.

Controls:

Handlebar, levers, cables, and foot controls service and adjustment.

Wheels And Tires:

Wheel bearing service, tire replacement, and balancing procedures.

Cooling System:

Engine cooling system (if applicable, though this is air-cooled, mention related components like oil cooler if present).

Exhaust System:

Exhaust component service and replacement.

Routine Maintenance:

Oil changes, filter replacements, spark plug service, air filter cleaning/replacement, brake fluid flush, drive belt inspection.

Troubleshooting:

Diagnostic flowcharts and symptom-based troubleshooting for common issues.

Major Repairs:

Engine rebuilds, transmission overhauls, fork seal replacement, clutch service.

Component Disassembly And Assembly:

Step-by-step instructions for removing and reinstalling all major and minor components.

Wiring Diagrams:

Detailed, color-coded wiring schematics for all electrical systems.

Torque Specifications:

Precise torque values for critical fasteners throughout the motorcycle.

Special Tools:

Identification and use of Harley-Davidson specific tools required for certain procedures.

Depth:

Comprehensive, from basic scheduled maintenance to complete engine and transmission rebuilds.

Diagnostics:

In-depth diagnostic procedures for electrical, fuel, and mechanical systems.

Specifications:

Detailed technical specifications for all components, including clearances, tolerances, and fluid capacities.

📊 Manual Specifications

Format:

PDF (Portable Document Format) - commonly distributed for digital manuals.

Resolution:

High-resolution scans ensuring clarity of text, diagrams, and images.

Searchability:

Typically includes searchable text for quick information retrieval.

Binding:

N/A (Digital Download - Printing and binding would be the user's responsibility)

Paper Type:

N/A (Digital Download)

⚙️ Engine Specifications

Engine Type:

Harley-Davidson Twin Cam 88 (or evolution thereof, typically 1450cc)

Displacement:

1450cc (88 cubic inches)

Configuration:

Air-cooled, 45-degree V-twin

Bore X Stroke:

Typically 3.75 in. x 4.00 in. (95.25 mm x 101.6 mm)

Valvetrain:

Overhead valves (OHV), 2 valves per cylinder

Horsepower:

Approximately 60-65 HP (at crankshaft, depending on specific tuning and exhaust)

Torque:

Approximately 75-80 lb-ft (at crankshaft, depending on specific tuning and exhaust)

Fuel Delivery:

Electronic Sequential Port Fuel Injection (ESPFI)

Fuel Type:

Unleaded gasoline, minimum 91 octane (RON+MON)/2)

Oil Capacity:

Approximately 4 quarts (3.8 liters) with filter change.

Oil Type:

Harley-Davidson SYN3 (Synthetic) SAE 20W-50 or equivalent API SG/SH/SJ/SL certified motorcycle oil.

🔧 Transmission

Type:

5-speed Cruise Drive Manual

Options:

N/A (Standard for this model)

Gear Ratios:

Specific gear ratios provided within the manual (e.g., 1st: 9.312, 2nd: 6.650, 3rd: 4.945, 4th: 3.812, 5th: 3.150 - illustrative, check manual for exact specs).

Final Drive:

Belt drive with primary chain drive to transmission.

Transmission Fluid:

Harley-Davidson Formula+ Transmission Lubricant or equivalent.

Capacity:

Approximately 1 quart (0.95 liters).

📐 Dimensions

Wheelbase:

Approximately 63.4 inches (1610 mm)

Length:

Approximately 99.5 inches (2527 mm)

Width:

Approximately 36.0 inches (914 mm) at handlebars

Height:

Approximately 56.8 inches (1443 mm) at windshield

Dry Weight:

Approximately 713 lbs (323 kg)

Gross Vehicle Weight Rating Gvwr:

Approximately 1160 lbs (526 kg)

Payload Capacity:

Approximately 447 lbs (203 kg)

🛡️ Safety Features

Crash Test Results:

Motorcycles of this era are not typically subjected to standardized crash testing like automobiles. Safety features focus on rider control and protection.

Brakes:

Hydraulically actuated disc brakes front and rear for effective stopping power. Dual front discs on some configurations.

Lighting:

Halogen headlight, taillight, brake light, and turn signals for visibility.

Suspension:

Stable handling characteristics provided by the chassis and suspension design.

Frame:

Sturdy steel frame designed for stability.

Fairing And Windshield:

Provides wind protection for the rider, reducing fatigue.

Saddlebags:

Secure storage for luggage, contributing to balanced weight distribution.

💡 Technology Features

Audio System:

Many Road King Custom models were equipped with an optional or standard AM/FM radio with CD player or cassette player, and handlebar-mounted controls.

Display:

Analog gauges for speedometer, tachometer, fuel level, and oil pressure, with indicator lights for various systems.

Cruise Control:

Often available as an option or standard on touring models, providing rider comfort on long journeys.

Security System:

Factory-installed security system with immobilizer and siren functionality was common.

Usb Port:

USB ports or auxiliary input jacks were less common in 2005 models, but some aftermarket integrations were available.

🔧 Maintenance

First Service:

Typically around 1,000 miles (1,600 km) for initial break-in service (oil change, filter, inspection).

Regular Maintenance:

Scheduled maintenance typically every 5,000 miles (8,000 km) or annually, whichever comes first (oil changes, drive belt tension, brake check, etc.). Specific intervals for spark plugs, air filters, and other components will be detailed in the manual.

Engine Oil:

Harley-Davidson SYN3 SAE 20W-50 or equivalent (API SG/SH/SJ/SL).

Transmission Oil:

Harley-Davidson Formula+ Transmission Lubricant or equivalent.

Primary Chain Case Oil:

Harley-Davidson Formula+ Transmission Lubricant or equivalent (shared with transmission in some Harley models, check specific setup).

Brake Fluid:

DOT 4 specification brake fluid.

Twin Cam 88 Common Points:

Early Twin Cam 88 engines can sometimes experience oil leaks, compensator sprocket wear, or cam chain tensioner issues (addressed in later revisions or aftermarket upgrades). The manual will guide diagnosis and repair.

Electrical Connectors:

Corrosion or looseness in electrical connectors can cause intermittent issues; the manual provides diagnostic steps.

Drive Belt:

Proper tension and inspection for wear are crucial to prevent premature failure.

📚 Vehicle History

Legacy:

Harley-Davidson, founded in 1903, is synonymous with American motorcycle culture, known for its V-twin engines and distinctive styling.

Road King Lineage:

The Road King platform has been a staple for Harley-Davidson since the early 1990s, evolving to incorporate new technologies while retaining its classic cruiser/touring appeal.

Custom Variant:

The 'Custom' variant (FLHRS) typically introduced more stylized elements, often with a lower ride height, different front fork rake, and unique cosmetic touches to set it apart.

Manufacturing Location:

Typically manufactured in Milwaukee, Wisconsin, USA, and York, Pennsylvania, USA.

Key Milestones:

The introduction of the Twin Cam engine platform in 1999 was a significant evolution, replacing the Evolution engine.

🏆 Awards & Recognition

Industry Acclaim:

Harley-Davidson motorcycles, particularly the touring models, consistently receive praise for their comfort, styling, and the distinct riding experience they offer. While specific awards for the 2005 FLHRS are not easily quantifiable, the model was well-regarded within its segment for its blend of classic style and touring utility.